Product Portion Enrobing Process and Apparatus, and Resulting Products

ABSTRACT

A method of enrobing a product portion in polymer strands includes mounting at least one product portion on a holding device and passing the at least one product portion through a polymer enrobing zone. The polymer enrobing zone can include a flow of polymeric fibers produced by a polymer spray head. The polymer fibers can wraparound the at least one product portion to produce an enrobed product portion. The holding device can hold the at least one product portion by passing at least partially through the body of the product portion. At least a portion of the holding device is removed from the enrobed product portion. In some cases, the at least one product portion includes smokeless tobacco.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. §119(e)to U.S. Application No. 61/786,295 filed Mar. 14, 2013. The priorapplication is incorporated herein by reference in its entirety.

FIELD

This disclosure generally relates to processes and machines for enrobingproduct portions with polymeric fibers, and the resulting enrobedproducts. In some cases, portions of smokeless tobacco can be enrobed inpolymeric fibers to create a fiber-wrapped smokeless tobacco product.

BACKGROUND

Smokeless tobacco is tobacco that is placed in the mouth and notcombusted. There are various types of smokeless tobacco, including:chewing tobacco, moist smokeless tobacco, snus, and dry snuff. Chewingtobacco is coarsely divided tobacco leaf that is typically packaged in alarge pouch-like package and used in a plug or twist. Moist smokelesstobacco is a moist, more finely divided tobacco that is provided inloose form or in pouch form and is typically packaged in round cans andused as a pinch or in a pouch placed between a cheek and gum of an adulttobacco consumer. Snus is a heat treated smokeless tobacco. Dry snuff isfinely ground tobacco that is placed in the mouth or used nasally.

Smokeless tobacco can be pouched in a permeable fabric using a pouchingmachine where a supply of pouching material is sealed around a depositof smokeless tobacco material. Such a pouch holds the tobacco in place,while at the same time letting the flavours and substances of thetobacco pass through the walls of the pouch and into the mouth of anadult tobacco consumer. A conventional pouching machine may form asupply of pouching material around a (or the) tube, seal the edges ofthe pouching material to form a tube of pouching material, form across-seal to form a bottom of the pouch, deliver an amount of smokelesstobacco through the tube and into the bottom-sealed pouch, move thebottom-sealed pouch off the tube, and form a second cross seal above thesmokeless tobacco to close the pouch. The second cross seal can also beused as the bottom seal for a subsequent pouch as the process continues.Individual pouches can be cut at the cross-seals. FIG. 7 depicts anexample of a pouched smokeless tobacco product made using a traditionalpouching machine.

SUMMARY

Methods and machines provided herein can be used to enrobe a productportion (e.g., a smokeless tobacco product portion) with polymericfibers. Polymeric fiber enrobed product portions can be used in a numberof consumer products, such as smokeless tobacco products and herbalproducts (e.g., tea). As compared to a conventional pouch made using aconventional pouching machine, a fiber-wrapped smokeless tobacco portionmade using the methods and machines provided herein can have an improvedmouth feel (e.g., no discernible seams), be more permeable, and/or bemore chewable. Methods and machines provided herein can be used toefficiently and reliably enrobe multiple product portions.

Methods of enrobing a product portion in polymer strands provided hereincan include mounting at least one product portion on a holding deviceand passing the at least one product portion through a polymer enrobingzone. The polymeric enrobing zone can be formed by using a polymer sprayhead to create a flow of polymeric fibers. The holding device can passat least partially through the body of the at least one product portion.The holding device can be moved to pass the at least one product portionthrough the polymer enrobing zone such that a plurality of the polymericfibers wraparound the at least one product portion to produce an enrobedproduct portion. At least a portion of said holding device can then beremoved from the enrobed product portion. The holding device can be anysuitable holding device.

In some cases, the holding device can be a needle. In some cases, theneedle can pass all the way through the body of the product portion. Insome cases, the needle can pass partly through the body of the productportion. In some cases, the needle can be inserted into the body to passbetween 30% and 90% through the thickness of the body. In some cases,the needle is metal. In some cases, the needle is polymeric. In somecases, the needle is fully removed from the product portion. In somecases, the needle is cut to leave a portion of the needle in an interiorof the body. In some cases, the needle is heated before, during, orafter the passing of the at least one product portion through thepolymer enrobing zone.

In some cases, the holding device can be a string. The string holdingdevice can be made out of any suitable material. In some cases, thestring holding device comprises of cellulosic fibers, polymeric fibers,or a combination thereof. In some cases, a string holding device can befood grade and cut without being removed form a product portion. In somecases, one or more product portions are mounted on the string holdingdevice by molding one or more product portions around the string holdingdevice. In some cases, multiple product portions can be on a singlestring. In some cases, removing at least a portion of the string holdingdevice is achieved by cutting the string to leave a portion of thestring in the interior of the product portion.

The holding device can move one or more product portions through thepolymer enrobing zone such that polymeric fibers wrap around and/orenrobe the at least one product portion. In some cases, the holdingdevice can rotate to expose multiple surfaces of one or more productportions to a stream of polymeric fibers exiting the polymer spray head.In some cases, the holding device can change orientations to exposemultiple surfaces of one or more product portions to a stream ofpolymeric fibers exiting the polymer spray head.

Methods provided herein can include a process of collecting at leastsome of said plurality of polymeric fibers on a polymer collectionroller positioned opposite the polymer enrobing zone. In some cases,fibers collected on the polymer collection roller can be recycled orused to make additional products.

An apparatus for enrobing a product portion provided herein can includea polymer spray head arranged to direct a flow of plurality of polymericfibers to create a polymer enrobing zone and one or more holding devicesadapted to move a product portion through the polymer enrobing zone. Insome cases, the at least one holding device is adapted to changeorientations and/or rotate to expose multiple surfaces of one or moreproduct portions to a flow of polymeric fibers in the polymer enrobingzone. In some cases, an apparatus provided herein can include a moldingdevice adapted to form at least one product portion in at least one moldcavity. In some cases, a molding device provided herein is adapted toform one or more product portions around the holding device. In somecases, an apparatus provided herein includes a robotic arm adaptedinsert one or more holding device into one or more mold cavities and tomove the holding device between the molding device and the polymerenrobing zone. In some cases, an apparatus provided herein includes acutting device adapted to cut at least a portion of the holding device.In some cases, an apparatus provided herein includes a heater to heatone or more holding devices. In some cases, an apparatus provided hereinincludes a polymer collection roller opposite the polymer enrobing zoneadapted to collect polymeric fibers that are not wrapped around productportions passed through the polymer enrobing zone. In some cases, anapparatus provided herein includes a polymer spray head that iselongated.

Methods and machines provided herein can, in some cases, direct moltenpolymer towards one or more product portions in the polymer enrobingzone such that the molten polymer naturally wraps around the threedimensional product portion. Molten polymer from one or more polymerspray heads can in the polymer enrobing zone can quickly solidify oncecooled to create a random orientation of meshed polymeric fibers thatcompletely wrap the product portion. In some cases, polymeric fibersprovided herein (e.g., polyurethane, polypropylene, etc.) can stick tothemselves after solidifying, which can avoid a need to seal a resultingenrobed product portion. For example, smokeless tobacco product portionsprovided herein can be enrobed in polyurethane and/or polypropylene toform a seamless outer layer, thus avoiding the seams commonly found inconventionally pouched smokeless tobacco products.

Product portions enrobed in methods and machines provided herein can beany suitable product. Product portions enrobed herein can be productswith sufficient integrity to not fall apart when levitated within thepolymer enrobing zone. In some cases, product portions enrobed inmethods provided herein include consumable products (e.g., tobacco,herbal products such as teas, mint, etc.). In some cases, productportions enrobed in methods provided herein have an overall ovenvolatiles content of about 4% by weight to about 61% by weight. In somecases, a binder can be included in the product portion to have theproduct portion retain its integrity during the enrobing processprovided herein. In some cases, a product portion can include between0.1 and 0.5 weight percent of a binder. Suitable binders include guargum, xanthan gum, cellulose gum, and combinations thereof.

In some cases, a fiber-wrapped product portion produced using methodsand machines provided herein can include a plurality of polymeric fiberssurrounding the product portion. The polymeric fibers overlying theproduct portion can have a basis weight of 40 grams per square meter(gsm) or less, 30 gsm or less, 20 gsm or less, 10 gsm or less, or 5 gsmor less. The polymeric fibers can have diameters of less than 100microns. In some cases, the polymeric fibers are melt-blown polymericfibers. In some cases, the polymeric fibers are force-spun polymericfibers. In some cases, an electrostatic charge can be applied to theplurality of polymeric fibers, one or more product portions, or acombination thereof. In some cases, a spin is applied to the productportions when passing through the polymer enrobing zone. In some cases,the polymer fibers wrap and seal the body of the product portionssimultaneously. In some cases, combinations of mouth-stable andmouth-dissolvable polymeric materials are combined to form afiber-wrapped product portion that becomes looser when consumed, yetremains generally cohesive. The polymeric fibers can also be a compositeof multiple materials, which may include both mouth-stable andmouth-dissolvable materials.

Fiber-wrapped smokeless tobacco products produced using methods andmachines provided herein provide a unique tactile and flavor experienceto an adult tobacco consumer. In particular, the polymeric fibers canprovide a smoother mouth texture and improved access to the smokelesstobacco, improved porosity, and improved fluid exchange as compared to atraditional pouching material, but still retain the smokeless tobacco.Moreover, the methods provided herein can result in a seamless wrappingof polymeric fibers, which can reduce mouth irritation. Furthermore, insome cases, polymeric fibers (e.g., polyurethane fibers) provided hereincan be more elastic and can permit an adult tobacco consumer tochew/squeeze the fiber-wrapped smokeless tobacco product and mold theproduct into a desired shape (e.g., to comfortably conform the productbetween the cheek and gum). As compared to a typical pouch paper, thefiber wrappings produced using methods and machines provided herein canbe softer, have a lower basis weight, and act as less of a selectivemembrane. Additionally, methods and machines provided herein avoid aneed to use a cutting device and a sealing device, which are commonlyused in conventional packaging machines.

Products provided herein include seamless fiber-wrapped smokelesstobacco products that include a body comprising smokeless tobacco, aplurality of melt-blown or centrifugal force spun polymeric fiberssurrounding the smokeless tobacco, and a string segment passing throughsaid body. In some cases, a fiber-wrapped smokeless tobacco productincludes smokeless tobacco and a plurality of polymeric fiberssurrounding the smokeless tobacco. The polymeric fibers can have a basisweight of 30 grams per square meter (gsm) or less, 20 gsm or less, 10gsm or less, or 5 gsm or less. The polymeric fibers can have diametersof less than 100 microns. In some cases, the polymeric fibers aremelt-blown polymeric fibers. In some cases, the polymeric fibers areforce-spun polymeric fibers.

Products, methods, and machines described herein can also be applied toother orally consumable plant materials in addition to smokelesstobacco. For example, some non-tobacco or “herbal” compositions havealso been developed as an alternative to smokeless tobacco compositions.Non-tobacco products may include a number of different primaryingredients, including but not limited to, tea leaves, red clover,coconut flakes, mint leaves, citrus fiber, bamboo fiber, ginseng, apple,corn silk, grape leaf, and basil leaf. In some cases, such a non-tobaccosmokeless product can further include tobacco extracts, which can resultin a non-tobacco smokeless product providing a desirable mouth feel andflavor profile. In some cases, the tobacco extracts can be extractedfrom a cured and/or fermented tobacco by mixing the cured and/orfermented tobacco with water and/or other solvents and removing thenon-soluble tobacco material. In some cases, the tobacco extracts caninclude nicotine. In some cases, a pouched non-tobacco product has anoverall oven volatiles content of between 10 and 61 weight percent.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the methods and compositions of matter belong. Althoughmethods and materials similar or equivalent to those described hereincan be used in the practice or testing of the methods and compositionsof matter, suitable methods and materials are described below. Inaddition, the materials, methods, and examples are illustrative only andnot intended to be limiting. All publications, patent applications,patents, and other references mentioned herein are incorporated byreference in their entirety.

DESCRIPTION OF DRAWINGS

FIG. 1 depicts an exemplary flow diagram showing an exemplary methodprovided herein.

FIG. 2A depicts an exemplary embodiment of an apparatus provided hereinincluding a robotic arm and needle holding devices.

FIG. 2B depicts additional details of the needle holding device of FIG.2A.

FIG. 3 depicts an exemplary embodiment of an apparatus provided hereinforming product portions on string holding devices.

FIG. 4 depicts an exemplary arrangement of polymer orifices and airorifices for a melt-blowing apparatus.

FIGS. 5A-5E illustrates a force-spinning apparatus.

FIG. 6 depicts an exemplary fiber-wrapped smokeless tobacco productportion.

FIG. 7 depicts a chart comparing release rates of methyl sallylate frompouches made of different materials.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Methods and machines provided herein can be used to enrobe one or moreproduct portions (e.g., smokeless tobacco product portions) withpolymeric fibers. Methods and machines provided herein can be used toefficiently and reliably enrobe multiple product portions. Methods andmachines provided herein can distribute polymeric fibers onto a productportion evenly across all surfaces of a product portion. In some cases,methods and machines provided herein can achieve a uniform applicationof polymeric fibers on all sides of multiple product portions in anautomated process. Fiber-wrapped smokeless tobacco product portionsprovided herein include a body including smokeless tobacco enrobed withpolymeric fibers.

Methods and machines provided herein achieve a desired coverage of oneor more product portion with polymeric fibers by controlling a movementof one or more product portions in a polymer enrobing zone. Methods andmachines provided herein mount one or more product portions on a holdingdevice and use holding device to move the one or more product portionsin a polymer enrobing zone. In some cases, methods and machines providedherein can minimize gaps produced due to the presence of the holdingdevice. In some cases, methods and machines provided herein can beadapted such that at least a portion of the holding device can beremoved without damaging the enrobed product portion. In some cases,methods and machines provided herein can be adapted such that a portionof the holding device remains a part of one or more enrobed productportions. Methods and machines provided herein can keep product portionsin the polymer enrobing zone for a desired amount of time a plurality ofdifferent orientations.

Polymer enrobing zone can be created by a polymer spray head. The flowof polymeric fibers out of the polymer spray head can cause polymericfibers to adhere to the one or more product portions and/or wrap aroundthe one or more product portions. Product portions held by a holdingdevice provided herein can be introduced to the polymer enrobing zoneand rotated about one, two, three, or more axes in order to achievedesired coating thicknesses. In some cases, machines provided hereininclude a controller adapted to move one or more holding devices along apre-programmed path in order to enrobe product portions according to adesired polymer-fiber coating thickness.

In some cases, the holding device can be a needle. For example, FIGS. 1,2A, and 2B depict exemplary embodiments that include needle holdingdevices that penetrate a product portion. In some cases, the needle canpass all the way through the body of the product portion. In some cases,the needle can pass partly through the body of the product portion. Insome cases, the needle can be inserted into the body to pass between 30%and 90% through the thickness of the body. In some cases, the needle ismetal. In some cases, the needle is polymeric. In some cases, the needleis fully removed from the product portion. In some cases, the needle iscut to leave a portion of the needle in an interior of the body. In somecases, the needle is heated before, during, or after the passing of theproduct portion through the polymer enrobing zone.

In some cases, the holding device can be a string. For example, FIG. 3depicts an exemplary embodiment that includes string holding devicesthat each pass through a plurality of product portions. The stringholding device can be made out of any suitable material. In some cases,the string holding device comprises cellulosic fibers, polymeric fibers,or a combination thereof. In some cases, one or more product portionsare mounted on the string holding device by molding one or more productportions around the string holding device. In some cases, multipleproduct portions can be on a single string. In some cases, removing atleast a portion of the string holding device is achieved by cutting thestring to leave a portion of the string in the interior of the productportion.

FIG. 1 depicts a process flow diagram showing an example of how productportions 104 can be formed, mounted, enrobed, and separated. In step A,a molding device 102, including mold cavities corresponding to a shapeof the product portions 104, can be used to mount product portions 104in the cavities to holding device 120. For example, a mixture ofsmokeless tobacco can be compressed in a mold cavity between oppositepistons to form a body that can hold its shape when ejected from themold cavities. In some cases, mold 102 can eject one or more productportions 104 onto holding device 120 such that one or more projections122 penetrate into the body of each product portion 104. In some cases,projections 122 are needles. In step B, one or more projections 122 canbe heated. Heating projections 122 can inhibit polymer build up onprojections 122 during the process. In some cases, heating projections122 can melt bond fibers on a product portion adjacent each projection.In some cases, one or more projections 122 are induction heated by aninduction heater 130.

In step C, holding device 120 move product portions 104 into a polymerenrobing zone 112 produced by a polymer spray head 110. Polymer sprayhead 110 can produce any suitable stream of polymeric fibers using anysuitable method. In some cases, polymer spray head 110 can be amelt-blowing apparatus. In some cases, polymer spray head 110 can be anelectro spinning apparatus. In some cases, polymer spray head 110 can bea force-spinning apparatus. As holding device 120 moves product portions104 through polymer enrobing zone 112, polymeric fibers begin to wraparound product portions 104 to create partially enrobed product portions106. Holding device 120 can rotate each projection 122 (e.g., needle)using rotating each projection 122 using rotator 124. In some cases,holding device 120 can be rotated around a variety of axes. In somecases, holding device 120 can introduce product portions 104 intopolymer enrobing zone 112 using multiple approaches. In some cases,holding device 120 can remove product portions 104 from polymer enrobingzone 112 using multiple departure angles. After enrobed product portions108 are removed from the polymer enrobing zone 112, enrobed productportions 108 are separated from holding device 120 in Step D, where oneor more enrobed product portions 108 can be collected and packaged. InStep E, holding device 120 can be returned to repeat the process. Insome cases, step E can include cleaning steps prior to repeating StepsA-E. Accordingly, methods and machines provided herein can be automatedand achieve consistent enrobed product properties.

FIG. 2A depicts an exemplary embodiment of an enrobing apparatus 200 forpreforming the method depicted in FIG. 1. FIG. 2B depicts additionaldetails of the holding 220 in FIG. 2A. As shown in FIG. 2A, a roboticarm 260 is attached to a holding device 220. As shown, product portions204 can be formed in mold 202, and collected by holding device 220 byinserting needles 222 into product portions 204. Robot arm 260 can moveholding device 220 into polymer enrobing zone 212 along a plurality ofaxes. FIG. 2B depicts additional details about holding device 220.Holding device 220 includes an axis 229 that can be rotated by a roboticarm 260 to turn a plurality of needles 222 by engaging gears 228 usingbelts 226. Each needle 222 can be connected to a pedestal 224, which caninclude a thermal coupling to each needle 222 and/or a rotationmechanism. In some cases, apparatus 200 can include a controller adaptedto move robot arm 260 along a desired path to achieve desired polymericfiber coating thicknesses. As shown, partially enrobed product portions206 are positioned in polymer enrobing zone 212 by robot arm 260. Afterthe enrobing process is complete, robot arm 260 can move holding device260 to a stripping device 282 including strippers 271, 272, 273, 274,and 275 that correspond to the spacing of the needles 222 of holdingdevice 220. After being stripped, enrobed product portions can becollected in collection basket 284. Enrobed product portions can then betransported for packaging.

In some cases, duel needles 222 are hold each product portion 204. Duelneedles 222 can be used to allow for a controlled rotation of productportions 204 by moving holding device 220. In some cases, a singleneedle may simply rotate relative to a product portion instead ofrotating the product portions, but two needles can be rotated to ensurea rotation of a product portion. Use of duel needles can also reduce across-sectional area of each holding device. In some cases, duel needlescan have circular cross-sectional areas. In some cases, both singleneedles and duel needles can be used with non-circular cross-sectionalareas.

In some cases, not shown, two needle-like devices can be pushed intoopposite sides of a product portion to secure the product portion. Theneedle-like devices can be made of metal and have a sharp point. In somecases, a single dowel can be pressed through the entire body to hold thebody. In some cases, the needle(s) or dowel(s) can have a diameter thatis sufficiently small so as to prevent the passage of significantamounts of tobacco through the uncovered portion of the body created bythe needle(s) and/or dowel(s).

FIG. 3 depicts an exemplary embodiment of an enrobing process includingstring holding devices 332. As shown, strings 332 can be unwound fromreel 330 and positioned cavities 303 of rotary mold 302. In some cases,each cavity 303 can be prefilled material and subsequently squeezed by aroller to form a plurality of product portions of each string 332. Insome cases, material for product portions is introduced to mold cavities303 after string 332 and compressed in to product portions in cavities303. Rotary mold 302 can include grooves to receiving and aligningstrings 332. After product portions 304 are molded around strings 332,the strings and product portions can be advanced towards polymerenrobing zones 312 a and 312 b on conveyor 340 moving between roller 344and 342. At a first polymer enrobing zone 312 a, a first polymer sprayhead 310 a directs polymeric fibers in a first direction to create apartially enrobed product portion 306, which then moves to a secondpolymer enrobing zone 312 b that directs polymeric fibers in a directionopposite the first direction. Second polymer spray head 310 b directspolymeric fibers in a direction opposite the first polymer spray head310 a in order to enrobe an opposite side. Stray polymeric fibers fromeach polymer spray head 310 a and 310 b can be collected on collectionrollers 314 a and 314 b, and removed as a scrap sheet 316 a or 316 b.

In some cases, rotary mold 302 can mold two opposite halves of a productportion on a string 332. The two opposite halves can be centered oroffset on a string. The two opposite halves can include differentconstituents. For example, in some cases, a smokeless tobacco productcan include one half including long cut tobacco and a second halfincluding fine cut tobacco. In some cases, each half can include adifferent flavor. After enrobing each half with polymeric fibers, thetwo opposite halves can be pressed and/or heat bonded together to createa duel material enrobed product portion, with or without removing string332.

Enrobed product portions on strings 332 can be moved to a cutting device390 by conveyor 370 moving on rollers 372 and 374. Cutting device 390can cut the string adjacent to each side of each enrobed productportion. A segment of string can thus remain in enrobed product portion308. String 332 can be made out of any suitable material. In some cases,string 332 is made out of a food grade material approved by anappropriate regulatory authority for oral and/or medical products.Suitable string materials include nylon, polyethylene, polypropylene,polyurethane, cotton yarn, nylon, rayon, polyesters, cellulosic fibers,and other food grade materials. In some cases, strings can be made ofcellulosic fibers that can degrade and/or dissolve over time due toproduct moisture and/or use. In some cases, string 332 is not rotate. Insome cases, string 332 can be rotated about its axis.

Polymer spray heads provided herein can provide any suitable supply ofpolymeric fibers using any suitable method to produce polymeric fibers.In some cases, polymer spray heads provided herein can be melt-blowingdevices and product portions can be passed through a stream ofmelt-blown polymeric fibers to form an outer layer of melt-blownpolymeric fibers around the product portions. In some cases, polymerspray heads provided herein can be force spinning devices and productportions can be passed through a stream of force-spun polymeric fibersto form an outer layer of force-spun polymeric fibers around the body.In some cases, polymeric structural fibers can be produced and contactedwith product portions while the polymeric fibers are still above theirmelt temperature. In some cases, polymeric structural fibers can becooled (e.g., quenched) prior to contacting or when fibers contact theproduct portion. In some cases, the polymeric structural fibers aretreated with a surfactant and/or other additives to increasepermittivity of the fiber wrapping. In some cases, polymeric fibers canbe hyper quenched during deposition.

In some cases, needle(s), string(s) and/or dowel(s) provided herein canhave a diameter of less than 500 microns, less than 100 microns, lessthan 50 microns, or less than 10 microns. The holding devices can beused to control the speed of movement of the body through the polymerenrobing zone.

The holding devices can be heated. A heated needle and/or dowel canminimize build-up of excess fibers on the needle or dowel while the bodyis being wrapped with the polymeric fibers. For example, an electricheater can be applied to a metal needle by heating a portion of theneedle being held. In some cases, holding devices can be heated byinduction. In some cases, multiple holding devices can be used to rotatethe bodies through the polymer enrobing zone along different axes. Forexample, two pairs of needles could be selectively engaged with a bodyto rotate a body about a first axis that is acute with the direction ofthe polymer flow followed by as second axis that is perpendicular to thefirst axis and acute with the direction of polymer flow. Other motionprofiles are also possible. After a body is wrapped (e.g., enrobed),they can be ejected from the holding device(s). For example, a pair ofneedles can be moved apart to allow a body to drop. In some cases, aplate can slide over a surface of a holding device to eject the body.

Molding Product Portions

Referring back to FIG. 1, product portions can be molded in a moldingdevice 102. In some cases, product portion is preformed or obtained in adesired size and/or shape. In some cases, as discussed above, productportion can include tobacco or other loose material. In order to moldproduct portions 104 out of loose material, the loose material can beadded to a mixer. An optional binder, and optionally flavorants and/orother additives can be mixed with the tobacco and/or other loosematerial. For example, the loose material can be long cut tobacco havingan oven volatiles content of 10-61 weight percent. Optional binder canbe TICALOID LITE Powder. Optional flavorants and other additives caninclude, for example, a mint flavoring, a sweetener, and a pH modifier.The mixing step can occur in any commercially available countertop mixeror industrial mixer, for example a HOBART 40 lbs mixer or a FORBERG 250lbs Paddle Mixer. In some cases, water can be added to the loosematerial (e.g., tobacco) prior to or during the mixing process to alterthe total oven volatiles content of the final enrobed product portion.The oven volatiles content can also be modified by heating the mixture.In some cases, a commercially available smokeless tobacco product (e.g.,SKOAL Long Cut) can be mixed with a binder (e.g., TICALOID LITE Powder)to form the mixture, which can then be shaped into one or more bodies.

In some cases, product portions provided herein can have less than 1% byweight of binder, less than 0.5% by weight of binder, less than 0.3% byweight of binder, less than 0.2% by weight of binder, less than 0.1% byweight of binder, or less than 0.05% by weight of binder. In some cases,smokeless tobacco bodies include one or more binders, such as ahydrocolloid, in an amount of between 0.05 weight percent and 0.8 weightpercent. In some cases, the smokeless tobacco products include between0.1 weight percent and 0.5 weight percent binder. For example, thepreformed smokeless tobacco products can include between 0.2 and 0.4weight percent of a binder that includes guar gum, xanthan gum,cellulose gum, or similar materials, or a combination thereof. In somecases, pre-hydrated Arabic gum can be used in product portions (e.g.,smokeless tobacco products) to act as an emulsifier to increase/improveflavor immediacy.

Mixing can include depositing the mixture into a mold. In some cases,the mixture is deposited into an open mold plate including a pluralityof identically shaped cavities, such as shown in FIG. 1. The moldingstep can include applying pressure to the mixture. The pressure can beapplied as injection pressure applied to the mixture as it is forcedinto a closed cavity or by compressing each cavity filled with themixture. The pressure used during the molding process impacts thatamount of compression experienced by the mixture and thus the materialproperties of the mixture. In some cases, 50-300 lbs. of injectionpressure is used to deliver the mixture into a plurality of moldcavities. The molds can be filled with continuous or intermittentpressure. A screw pump can be used to apply the pressure to the mixture.For example, a FORMAX® machine (e.g., the FORMAX F-6 and F-19 units) canbe used to inject the mixture into cavities in a mold plate. Forexample, such a process is described in U.S. Patent ApplicationPublication No. 2012/0024301, which is hereby incorporated by reference.In some cases, the mold cavities have shapes corresponding to thepreformed product shapes shown in FIGS. 1B, 1C, and 4A-4N. In somecases, the mold cavities can have other shapes. In some cases, the moldcavities have a volume sized to create shaped smokeless tobacco bodieshaving a mass of, for example, about 2.35 grams. The edges and cornersof the mold can be rounded to permit the shaped smokeless tobacco bodiesto be easily released from the mold and be comfortable in the mouth ofan adult tobacco consumer. In some cases, the molding step can includeextruding smokeless tobacco material (optionally with binders,flavorants, and other additives) and cutting the extruded smokelesstobacco material to form the preformed bodies.

Polymer Enrobing Zone

Polymer enrobing zones provided herein can include a flow of polymericfibers produced by any suitable polymer spray head. In some cases,multiple streams of polymeric fibers can be directed towards a productpath along different directions. For example, a single melt-blowingdevice can have a bent or curved array of spinnerets so that melt-blownpolymeric fibers converge towards a drop path. In some cases, multiplepolymer fiber producing devices are arranged so that multiple streamsconverge towards a product path. In some cases, multiple polymerproducing devices are arranged in series along a drop path directed indifferent directions (e.g., opposite directions). In some cases, asingle product portion can be passed through one or more streamsmultiple times.

In some cases, an electrostatic charge can be applied to the bodiesand/or the polymer during step. When electrostatically charged, apreformed body can draw fibers directly onto the body, which canincrease the efficiency of the wrapping process and minimize polymericfibers that bypass the body. An electrostatic charge can also improvethe coverage around the back side of the preformed body. In some cases,a holding device (e.g., one or more needle-like structures pushed intothe body) can be used to apply an electrostatic charge to the body. Insome cases, the polymer is electrostatically charged (e.g., as thepolymer passes through the spinnerets).

The fibers in polymer enrobing zone can be produced by melt-blowingand/or centrifugal force spinning, which are each described below. Thepolymer can be any suitable polymers usable in a melt-blowing and/orcentrifugal force spinning process, such as polypropylene, polyurethane,cellulose, polyethylene, PVC, EVA (ethyl vinyl acetate), viscose,polyester, and PLA. Suitable polymeric materials for the fibers includeone or more of the following polymer materials: acetals, acrylics suchas polymethylmethacrylate and polyacrylonitrile, alkyds, polymer alloys,allyls such as diallyl phthalate and diallyl isophthalate, amines suchas urea, formaldehyde, and melamine formaldehyde, epoxy, cellulosicssuch as cellulose acetate, cellulose triacetate, cellulose nitrate,ethyl cellulose, cellulose acetate, propionate, cellulose acetatebutyrate, hydroxypropyl cellulose, hydroxypropyl methyl cellulose,carboxymethyl cellulose, cellophane and rayon, chlorinated polyether,coumarone-indene, epoxy, polybutenes, fluorocarbons such as PTFE, FEP,PFA, PCTFE, ECTFE, ETFE, PVDF, and PVF, furan, hydrocarbon resins,nitrile resins, polyaryl ether, polyaryl sulfone, phenol-aralkyl,phenolic, polyamide (nylon), poly (amide-imide), polyaryl ether,polycarbonate, polyesters such as aromatic polyesters, thermoplasticpolyester, PBT, PTMT, (polyethylene terephthalate) PET and unsaturatedpolyesters such as SMC and BMC, thermoplastic polyimide, polymethylpentene, polyolefins such as LDPE, LLDPE, HDPE, and UHMWPE,polypropylene, ionomers such as PD and poly allomers, polyphenyleneoxide, polyphenylene sulfide, polyurethanes (such as DESMOPAN DP 9370Aavailable from Bayer), poly p xylylene, silicones such as siliconefluids and elastomers, rigid silicones, styrenes such as PS, ADS, SAN,styrene butadiene latricies, and styrene based polymers, suflones suchas polysulfone, polyether sulfone and polyphenyl sulfones, polymericelastomers, and vinyls such as PVC, polyvinyl acetate, ethyl vinylacetate, polyvinylidene chloride, polyvinyl alcohol, polyvinyl butyrate,polyvinyl formal, propylene-vinyl chloride copolymer, ethylvinylacetate, and polyvinyl carbazole, polyvinyl pyrrolidone, andpolyethylene oxide, ethylene vinyl alcohol, sugar alcohols, andstarches. In some cases, a blend of polyurethane, polypropylene, andstyrene can be compounded and used to make polymeric fibers in methodsand machines provided herein.

The melt-blown and/or centrifugal force spun polymeric fibers can bequenched (i.e., rapidly cooled to below their melt temperature) prior toor upon contacting the product portions. For example, water or otherliquid can be sprayed into a polymeric fiber stream prior to contactwith a product portion to quench the polymeric fibers. In some cases,the polymeric fibers can be quenched with a surfactant. In some cases,the polymeric fibers can be cooled to below the melt temperature aftercontact with one or more product portions.

The polymeric fibers can have a diameter of less than 100 microns, lessthan 50 microns, less than 30 microns, less that 10 microns, less than 5microns, less than 1 microns, less that 0.5 microns, less than 0.1microns, less than 0.05 microns, or less than 0.01 microns. In somecases, melt-blown polymeric fibers can have a diameter of between 0.5and 5 microns. In some case, force-spun polymeric fibers can have adiameter of between 10 nanometers and 1 micron. The flow of thepolymeric fibers and the dimensions of the polymeric fibers as they exita melt blowing or centrifugal force spinning apparatus result in anintimate contact between the fibers and the product portions such thatthe polymeric fibers conform to the surface topography of the fibroustobacco structures.

Collecting and Packaging

A collecting and packaging step can include catching the enrobed productportions and packaging them in package (e.g., container). For example,fiber-wrapped smokeless tobacco products can be collected on a conveyorbelt and transported to a position device that places a plurality ofproducts in a container. After being placed in the interior space of acontainer, a lid can be mated with the connection rim of the bottomcontainer. A label can be applied to the closed container system (e.g.,applied to the outer cylindrical sidewalls of the bottom container andthe lid). Shrink wrap can also be applied to the closed containersystem. A plurality of filled, labeled, and shrink wrapped containersystems can then be placed in a box and shipped to a retail location.

For example, fiber-wrapped smokeless tobacco products described hereincan experience significant jarring movements during the landing afterthe drop, during sorting and placing the formed shaped smokeless tobaccobodies into a container, closing, labeling, shrink wrapping, and bulkpackaging the container, shipping containers to retail locations,stocking the containers at a retail location, and having an adulttobacco consumer purchase and carry around the container. Fiber-wrappedsmokeless tobacco products provided herein, however, can retain theirstructural integrity due to the fiber wrapping.

Melt-blowing Processes

Polymer spray heads 110, 210, and 310 can, in some cases, bemelt-blowing devices adapted to produce a plurality of polymeric fibers.Melt-blowing is an extrusion process where molten polymeric resins areextruded through an extrusion die (e.g., a spinneret) and gas isintroduced to draw the filaments to produce polymeric fibers. The gascan be heated air blown at high velocity through orifices that surroundeach spinneret or in air slots around each individual spinneret. In somecases, layers of hot air are blown through slots between rows ofspinnerets—the strands of polymeric material are attenuated by beingtrapped between two layers of air. Other methods of delivering theattenuating gas (e.g., heated air) are possible. FIG. 4 depicts anexemplary arrangement of polymer orifices and air orifices formelt-blowing devices 420. Other melt-blowing devices are described inU.S. Pat. Nos. 4,380,570; 5,476,616; 5,645,790; and 6,013,223, and inU.S. Patent Applications US 2004/0209540; US 2005/0056956; US2009/0256277; US 2009/0258099; and US 2009/0258562, which are herebyincorporated by reference.

A melt-blowing device 420 can include a polymer extruder that pushesmolten polymer at low or high melt viscosities through a plurality ofpolymer orifices 422. The melt-blowing device 420 includes one or moreheating devices that heat the polymer as it travels through themelt-blowing device 140 to ensure that the polymer remains above itsmelting point and at a desired melt-blowing temperature. As the moltenpolymer material exits the polymer orifice 422, the polymer material isaccelerated to near sonic velocity by gas being blown in parallel flowthrough one or more air orifices 424. The air orifices 424 can beadjacent to the polymer orifices 422. The air orifices 424 may surroundeach polymer orifice 422. In some cases, the air orifices 424 can berounded. Each combination of a polymer orifice 422 with surrounding airorifices 424 is called a spinneret 429. For example, the melt-blowingdevice 420 can have between 10 and 500 spinnerets 429 per square inch.The polymer orifices 422 and the gas velocity through gas orifices 424can be combined to form fibers of 100 microns or less. In some cases,the spinnerets each have a polymer orifice diameter of 30 microns orless. In some cases, the fibers have diameters of between 0.5 micronsand 5 microns. The factors that affect fiber diameter includethroughput, melt temperature, air temperature, air pressure, spinneretdesign, material, distance from the drum, spinneret design, and materialbeing processed. In some cases, the spinnerets 429 each have a polymerorifice diameter of less than 900 microns. In some cases, the spinnerets429 each have a polymer orifice diameter of at least 75 microns. Theaverage polymer orifice diameter can range from 75 microns to 1800microns. In some cases, the average polymer orifice diameter can bebetween 150 microns and 400 microns. In some cases, polymer orificediameters of about 180 microns, about 230 microns, about 280 microns, orabout 380 microns are used. In some cases, some spinnerets can alsoinclude orifices that provide air flows without polymer to provideadditional attenuation and direction of polymer fibers produced fromother spinnerets.

Electro Spinning Systems

Electro spinning is a process that spins fibers of diameters rangingfrom 10 nm to several hundred nanometers; typically polymers aredissolved in water or organic solvents. The process makes use ofelectrostatic and mechanical force to spin fibers from the tip of a fineorifice or spinneret. The spinneret is maintained at positive ornegative charge by a DC power supply. When the electrostatic repellingforce overcomes the surface tension force of the polymer solution, theliquid spills out of the spinneret and forms an extremely finecontinuous filament. These filaments are collected onto a rotating orstationary collector with an electrode beneath of the opposite charge tothat of the spinneret where they accumulate and bond together to formnanofiber web.

Centrifugal Force Spinning Processes

Centrifugal force spinning is a process where centrifugal force is usedto create and orient polymeric fibers. FIGS. 5A-5E depict an exemplarycentrifugal force spinning apparatus. As shown, a spinneret 520 holdspolymeric material 515 and is rotated at high speeds with a motor 550 toproduce polymeric fibers 530 that are deposited onto a fiber collector532. FIG. 5B depicts a close-up of the spinneret 520 showing twoorifices 522. Any number of orifices 522 can be used. The fibercollector 532 can be a continuous drum or a series of spaced collectionfingers. As the spinneret 520 rotates, the polymeric material (in aliquid state) is pushed to the orifices 522 lining the outer wall of thespinneret 520. As the polymeric material enters the orifice chamber,molecules disentangle and then align directionally. Centrifugal andhydrostatic forces combine to initiate a liquid material jet. Theexternal aerodynamic environment combined with the inertial force ofcontinued rotation further applies shear forces and promote coolingand/or solvent evaporation to further stretch the fiber. The inertiaforce can stretch molecular chains into the nanoscale and the airturbulence can apply a shear force. Product portions can be passedthrough the streams of centrifugal force spun polymer by using holdingdevices provided herein to move and/or rotate one or more productportions within polymer enrobing zone (e.g., in a collection drum 532).In some cases, centrifugal force spun fibers can improve a web strengthand random orientation of polymeric fibers deposited onto a productportion due to a long fiber length.

Polymeric Fibers

Polymeric fibers produced and used in and by methods, products, andmachines provided herein can be made of any suitable material by anysuitable method. In some cases, polymeric fibers from polymer sprayheads discussed herein can be produced by melt-blowing, electrospinning, and/or centrifugal force spinning, which are each describedabove. The polymer can be any suitable polymers usable in amelt-blowing, electro spinning, and/or centrifugal force spinningprocess, such as polypropylene, polyurethane, styrene, cellulose,polyethylene, PVC, viscose, polyester, and PLA. In some cases, polymericfibers can be quenched (i.e., rapidly cooled to below their melttemperature) prior to or upon contacting product portions 220. Forexample, water or other liquid can be sprayed into a polymeric fiberstream as it exits the polymer spray head. In some cases, the polymericfibers can be quenched with a surfactant. In some cases, the polymericfibers can be cooled to below the melt temperature after contact withproduct portions.

In some cases, the polymeric fibers are mouth-stable fibers. Themouth-stable fibers can have low extractables, are approved for use withfood, and/or be manufactured by suppliers who are GMP approved. Highlydesirable are materials that are easy to process and relatively easy toapprove for oral use (e.g. quality, low extractables, approved byregulators, suppliers are GMP approved). In some cases, the mouth-stablestructural fibers are elastomers. Elastomers can provide webs withimproved elongation and toughness. Suitable elastomers include VISTAMAX(ExxonMobil), TEXIN RXT70A (Bayer), and MD-6717 (Kraton). In some cases,elastomers can be combined with polyolefins at ratios ranging from 1:9to 9:1. For example, elastomers (such as VISTAMAX or MD-6717) can becombined with polypropylene.

In some cases, polymeric fibers used by methods, machines, and productsprovided herein include elastomeric polymers (e.g., polyurethane).Elastomeric polymers can provide webs with improved elongation andtoughness. In some cases, an elastomeric polymer smokeless tobaccoproduct portion provided herein can provide the unique property ofallowing an adult tobacco consumer to reduce or increase a packingdensity of the elastomeric polymer smokeless tobacco product portion,which can impact a rate of flavor release. A higher packing density canreduce a rate of flavor release. In some cases, polymeric fibers used inmethods and machines provided herein can be hydrophilic, which canprovide a moist appearance and/or provide superior flavor release.Suitable elastomeric polymers include EPAMOULD (Epaflex), EPALINE(Epaflex), TEXIN (Bayer), DESMOPAN (Bayer), HYDROPHAN (AdvanceSourseBiomaterials), ESTANE (Lubrizol), PELLETHANE (Lubrizol), PEARLTHANE(Merquinsa), IROGRAN (Huntsman), ISOTHANE (Greco), ZYTHANE (AlliancePolymers and Services), VISTAMAX (ExxonMobil), and MD-6717 (Kraton). Insome cases, elastomers can be combined with polyolefins at ratiosranging from 1:9 to 9:1. For example, elastomeric polymers can becombined with polypropylene.

Hydrophilic materials can wick fluids there through and/or give apouched product a moist appearance. For example, polyurethane polymerfibers can also provide faster and higher cumulative flavor release ascompared to non-elastic polymer fiber such as rayon, polypropylene, andpolyethylene terephthalate (PET). FIG. 7 depicts the cumulative methylsallylate concentration (μg/portion) measured in artificial salivafractions from USP-4 flow-through dissolution pouches made ofpolyurethane, polypropylene, rayon, and PET. Due to polyurethanesrelatively high level of elasticity and natural hydrophilic properties,flavor is able to traverse polyurethane pouching material easier thannon-elastomeric nonwoven substrates.

Mouth-dissolvable fibers could be made from hydroxypropyl cellulose(HPC), methyl hydroxypropyl cellulose (HPMC), polyvinyl alcohol (PVOH),PVP, polyethylene oxide (PEO), starch and others. These fibers couldcontain flavors, sweeteners, milled tobacco, and other functionalingredients. The fibers can, in some cases, be formed by extrusion or bysolvent processes. In some cases, mouth dissolvable fibers can becombined with mouth-stable fibers to wrap the bodies as provided herein.For example, alternating layers of mouth dissolvable fibers andmouth-stable fibers can be deposited on a body.

Colorants and/or fillers can also be added to the polymer inmelt-blowing device provided herein. The hydraulic permittivity of thefabric can also be increased by compounding the polymer with a fillerprior to melt-blowing the polymeric material. The hydraulic permittivityis the rate of fluid transfer through a substrate. In some cases, acolorant can be used as the filler. For example, a brown colorant can beadded to a feed hopper of the extruder along with a polymer material(e.g., polypropylene) prior to melt-blowing the polymer into the fibers.In addition to improving the hydraulic permittivity, the colorant canimprove the aesthetic appeal of the fiber-wrapped smokeless tobaccoproduct. For example, a brown colorant can make a wrappedmoist-smokeless tobacco product appear moist. The colorant and thepolymer can be compounded and pelletized prior to melt-blowing thepolymer to ensure a consistent ratio of colorant to polymer. In somecases, the colorant can be a liquid and can be injected into thepolymeric material.

In some cases, the filler can include milled tobacco material. Forexample, milled tobacco could be combined into a polymeric structuralfiber such that the polymeric material at least partially encapsulatesthe milled tobacco. For example, milled tobacco could be added to amolten polymer (e.g., polypropylene) in amounts of up to about 80% andextruded in a melt-blowing or centrifugal force spinning process. Themilled tobacco can provide a unique texture or consumer experience whilethe polymeric material remains mouth-stable and cohesive.

As discussed above, the polymeric fibers can contact product portions ata temperature greater than the melt temperature of the polymer. In somecases, however, the polymeric fibers can be quenched and/or treated witha surfactant prior to contacting product portions. Water vapor can beused to cool the polymeric material. For example, atomized water from aspout can be directed into the stream of molten strands of polymericmaterial to “quench” the polymeric strands and form the fibers. Forexample, a mist can be aimed towards the spinnerets 429 of themelt-blowing device 420. A fine mist of water vapor, surfactant, or aircan quickly cool the strands below the polymer melt temperature. In somecases, quenched melt-blown fibers can have improved softness andfiber/web tensile strength.

A surfactant treatment can also be applied to the fibers. In some cases,a surfactant is applied to the polymeric fibers as they exit thespinnerets 429 of the melt-blowing device 420 or the orifices 522 of thecentrifugal force spinning spinneret 520. In some cases, surfactant canbe applied as a mist (either with or without water). In some cases, thesurfactant applied as a mist can quench the polymeric fibers. In somecases, the surfactant can be applied in an extrusion process. In somecases, a mixture of water and surfactant can be atomized and applied asa mist. Sweeteners and/or flavorants can also be atomized and applied tothe polymeric fibers in mist, which can also be used to quench thepolymeric fibers.

Quenching the polymer can modify the crystallinity of the polymermaterial to improve tensile strength and mouth feel. The surfactant canimprove the hydraulic permittivity of the fiber wrap to improve moistureand flavor release from the product. The hydraulic permittivity is therate of fluid transfer through a substrate.

The tensile integrity of the wrapped fiber can also be improved bybonding fibers together. In some cases, the wrapped fiber can be heatbonded at intersection points. The heating of the polymeric material toa temperature above its melt temperature can be accomplished by usingelectrically heated surfaces, ultrasonic bonding, infrared energy, radiofrequency energy, microwave energy, laser, and/or needle punching.Stitch bonding, point bonding, and quilting are methods of applyingpatterns to nonwoven fabrics. These are forms of thermal bondingtypically achieved with ultrasonic bonding processes, although otherenergy sources and related equipment can be used to create particularpatterns of bonding within the network of fibers.

Smokeless Tobacco Product Portions

Fiber-wrapped smokeless tobacco products made using the methods andmachines provided herein can provide a smokeless tobacco product thatcan remain intact when used by an adult tobacco consumer, yet provide asatisfying tobacco flavor and tactile experience. In some cases,polymeric fibers have a diameter of less than 100 microns and aredeposited onto a body including smokeless tobacco held by the holdingdevices provided herein. The polymeric fibers can wrap around the bodyand form a moisture-permeable porous surface. In particular, thepolymeric fibers can provide a smooth mouth texture,bind/encase/encapsulate the smokeless tobacco during use, but give theadult tobacco consumer good access to the smokeless tobacco and anyflavor contained therein. As compared to a typical pouch paper (e.g., asshown in FIG. 7), the polymeric fibers can be softer, be free of seams,have a lower basis weight, act as less of a selective membrane, bechewable, and greater moldability/manageability. Methods and machinesdescribed herein result in products that remain cohesive and are lesslikely to break apart during packaging, handling, shipping, and duringuse by adult tobacco consumers. Methods and machines described hereincan enrobe and/or wrap smokeless tobaccos that are not suitable forbeing pouched using a typical pouching operation, for example smokelesstobaccos having an average aspect ratio of greater than 3 (e.g.,long-cut smokeless tobacco) and/or high moisture tobacco (e.g., atobacco having an OV content of greater than 47 weight percent).

The described combinations of the polymeric material and smokelesstobacco can provide a softer mouth feel. Moreover, in some cases, thepolymeric material can be elastic or pliable (e.g., a polymericpolyurethane such as DESMOPAN DP 9370A or TEXIN available from Bayer),thus forming a smokeless tobacco product that can tolerate being“worked” (e.g., chewed or squeezed) in the mouth without the tobaccodispersing within the mouth. For example, the smokeless tobacco productcan be worked to provide flavor and/or to comfortably conform betweenthe cheek and gum. In some cases, combinations of mouth-stable andmouth-dissolvable polymeric materials are combined with a body includingsmokeless tobacco material to provide a product that becomes looserafter being placed in a mouth of an adult tobacco consumer, yet remainsgenerally cohesive. Polymeric structural fibers can also be a compositeof multiple materials, which may include both mouth-stable andmouth-dissolvable materials.

The fiber-wrapped smokeless tobacco product can also be dimensionallystable. As used herein, “dimensionally stable” means that thefiber-wrapped smokeless tobacco product retains its shape under its ownweight. In some cases, a fiber-wrapped smokeless tobacco product isflexible, yet can be picked up at one end without the force of gravitycausing the fiber-wrapped smokeless tobacco product to bend or sag. Insome cases, the fiber-wrapped smokeless tobacco product can be easilydeformable. In some cases, enrobed product portions produced in methodsand/or machines provided herein can be rewet with water and/or asolution of flavorants, sweeteners, and/or other additives discussedherein to wick the coating of polymeric fibers, provide a moistappearance, prove a flavor immediately, and/or to increase a flavorintensity.

Tobacco

Smokeless tobacco is tobacco suitable for use in an orally used tobaccoproduct. By “smokeless tobacco” it is meant a part, e.g., leaves, andstems, of a member of the genus Nicotiana that has been processed.Exemplary species of tobacco include N. rustica, N. tabacum, N.tomentosiformis, and N. sylvestris. Suitable tobaccos include fermentedand unfermented tobaccos. In addition to fermentation, the tobacco canalso be processed using other techniques. For example, tobacco can beprocessed by heat treatment (e.g., cooking, steam treating, toasting),flavoring, enzyme treatment, expansion and/or curing. For example,tobacco can be conditioned by heating, sweating and/or pasteurizingsteps as described in U.S. Publication Nos. 2004/0118422 or2005/0178398. Both fermented and non-fermented tobaccos can be processedusing these techniques. In some cases, the tobacco can be unprocessedtobacco. Specific examples of suitable processed tobaccos include darkair-cured, dark fire-cured, burley, flue cured, and cigar filler orwrapper, as well as the products from the whole leaf stemming operation.In some cases, smokeless tobacco includes up to 70% dark tobacco on afresh weight basis. Fermenting typically is characterized by highinitial moisture content, heat generation, and a 10 to 20% loss of dryweight. See, e.g., U.S. Pat. Nos. 4,528,993; 4,660,577; 4,848,373; and5,372,149. In addition to modifying the aroma of the leaf, fermentationcan change the color, texture, taste, and sensorial attributes of aleaf. Also during the fermentation process, evolution gases can beproduced, oxygen can be taken up, the pH can change, and the amount ofwater retained can change. See, for example, U.S. Publication No.2005/0178398 and Tso (1999, Chapter 1 in Tobacco, Production, Chemistryand Technology, Davis & Nielsen, eds., Blackwell Publishing, Oxford).Cured, or cured and fermented tobacco can be further processed (e.g.,cut, expanded, blended, milled, or comminuted) prior to incorporationinto the smokeless tobacco product. The tobacco, in some cases, is longcut fermented cured moist tobacco having an oven volatiles content ofbetween 10 and 61 weight percent prior to mixing with the polymericmaterial and optionally flavorants and other additives.

The tobacco can, in some cases, be prepared from plants having less than20 μg of DVT per cm² of green leaf tissue. For example, the tobaccoparticles can be selected from the tobaccos described in U.S. PatentPublication No. 2008/0209586, which is hereby incorporated by reference.Tobacco compositions containing tobacco from such low-DVT varietiesexhibits improved flavor characteristics in sensory panel evaluationswhen compared to tobacco or tobacco compositions that do not havereduced levels of DVTs.

The smokeless tobacco can be processed to a desired size. For example,long cut smokeless tobacco typically is cut or shredded into widths ofabout 10 cuts/inch up to about 110 cuts/inch and lengths of about 0.1inches up to about 1 inch. Double cut smokeless tobacco can have a rangeof particle sizes such that about 70% of the double cut smokelesstobacco falls between the mesh sizes of −20 mesh and 80 mesh. Otherlengths and size distributions are also contemplated.

The smokeless tobacco can have a total oven volatiles content of about10% by weight or greater; about 20% by weight or greater; about 40% byweight or greater; about 15% by weight to about 25% by weight; about 20%by weight to about 30% by weight; about 30% by weight to about 50% byweight; about 45% by weight to about 65% by weight; or about 50% byweight to about 60% by weight. Those of skill in the art will appreciatethat “moist” smokeless tobacco typically refers to tobacco that has anoven volatiles content of between about 40% by weight and about 60% byweight (e.g., about 45% by weight to about 55% by weight, or about 50%by weight). As used herein, “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110 degrees C. for 3.25hours. The fiber-wrapped smokeless tobacco product can have a differentoverall oven volatiles content than the oven volatiles content of thesmokeless tobacco used to make the fiber-wrapped smokeless tobaccoproduct. The processing steps described herein can reduce or increasethe oven volatiles content. The overall oven volatiles content of thefiber-wrapped smokeless tobacco product is discussed below.

The fiber-wrapped smokeless tobacco product can include between 15weight percent and 85 weight percent smokeless tobacco on a dry weightbasis. The amount of smokeless tobacco in a fiber-wrapped smokelesstobacco product on a dry weight basis is calculated after drying thefiber-wrapped smokeless tobacco product in a pre-warmed forced draftoven at 110 degrees C. for 3.25 hours. The remaining non-volatilematerial is then separated into tobacco material and polymeric material.The percent smokeless tobacco in the fiber-wrapped smokeless tobaccoproduct is calculated as the weight smokeless tobacco divided by thetotal weight of the non-volatile materials. In some cases, thefiber-wrapped smokeless tobacco product includes between 20 weightpercent and 60 weight percent tobacco on a dry weight basis. In somecases, the fiber-wrapped smokeless tobacco product includes at least 28weight percent tobacco on a dry weight basis. For example, afiber-wrapped smokeless tobacco product can include a total ovenvolatiles content of about 57 weight percent, about 3 weight percentpolymeric material, and about 40 weight percent smokeless tobacco on adry weight basis.

In some cases, a plant material other than tobacco is used as a tobaccosubstitute in the fiber-wrapped smokeless tobacco product. The tobaccosubstitute can be an herbal composition. Herbs and other edible plantscan be categorized generally as culinary herbs (e.g., thyme, lavender,rosemary, coriander, dill, mint, peppermint) and medicinal herbs (e.g.,Dahlias, Cinchona, Foxglove, Meadowsweet, Echinacea, Elderberry, Willowbark). In some cases, the tobacco is replaced with a mixture ofnon-tobacco plant material. Such non-tobacco compositions may have anumber of different primary ingredients, including but not limited to,tea leaves, coffee, red clover, coconut flakes, mint leaves, ginseng,apple, corn silk, grape leaf, and basil leaf. The plant materialtypically has a total oven volatiles content of about 10% by weight orgreater; e.g., about 20% by weight or greater; about 40% by weight orgreater; about 15% by weight to about 25% by weight; about 20% by weightto about 30% by weight; about 30% by weight to about 50% by weight;about 45% by weight to about 65% by weight; or about 50% by weight toabout 60% by weight.

Binders

Binders can optionally be used to bind together smokeless tobaccomaterial to form a body, which can then be encased or wrapped withpolymeric fibers. Binders suitable for use in the fiber-wrappedsmokeless tobacco product provided herein include orally compatiblepolymers, such as cellulosics (e.g., carboxymethyl cellulose (CMC),hydroxypropyl cellulose (HPC), hydroxyethyl cellulose (HEC),hydroxypropyl methyl cellulose (HPMC), and methyl cellulose (MC));natural polymers (e.g., starches and modified starches, konjac,collagen, inulin, soy protein, whey protein, casein, and wheat gluten);seaweed-derived polymers (e.g., carrageenan (kappa, iota, and lambda);alginates, (and propylene glycol alginate), microbial-derived polymers(e.g., xanthan, dextrin, pullulan, curdlan, and gellan); extracts (e.g.,locust bean gum, guar gum, tara gum, gum tragacanth, pectin (lo methoxyand amidated), agar, zein, karaya, gelatin, psyllium seed, chitin, andchitosan), exudates (e.g., gum acacia (arabic) and shellac), syntheticpolymers (e.g., polyvinyl pyrrolidone, polyethylene oxide, and polyvinylalcohol).

The binder, in some cases, is guar gum, xanthan, cellulose, or acombination thereof. The cellulose can be carboxymethyl cellulose (CMC).Guar gum, xanthan, CMC, and some combinations thereof can be obtainedfrom, for example, TIC Gums Inc., located in White Marsh, Md. and atwww.ticgums.com. Guar gum is sold by TIC Gums Inc. under the trade nameGUARNT. Carboxymethyl cellulose (CMC) is sold by TIC Gums Inc. under thetrade name TICALOSE. Xanthan is sold by TIC Gums Inc. under the tradename TICAXAN. TIC Gums Inc. also sells some mixed binders, such as themixed binder systems sold under the trade names TICALOID and TICAFILM.In some cases, TICALOID LITE Powder is used as the binder in thepreformed smokeless tobacco products.

The binder can be present in amounts that allow the fiber-wrappedsmokeless tobacco product to remain cohesive during a pass through apolymer enrobing zone. In some cases, the fiber-wrapped smokelesstobacco product includes at least 0.05 weight percent binder. Thefiber-wrapped smokeless tobacco product has, in some cases, less than5.0 weight percent binder. The fiber-wrapped smokeless tobacco producthas, in some cases, less than 1.0 weight percent binder. In some cases,the binder of each fiber-wrapped smokeless tobacco product is between0.05 and 0.5 weight percent of the preformed smokeless tobacco product.The binder of each fiber-wrapped smokeless tobacco product can also bein an amount of between 0.1 and 0.4 weight percent. In some cases, afiber-wrapped smokeless tobacco product made by methods or machinesprovided herein can be substantially free of binders.

Flavorants and Additives

Flavors and other additives can be included in the compositions andarrangements described herein and can be added to the fiber-wrappedsmokeless tobacco products at any point in the process of making thefiber-wrapped smokeless tobacco products. For example, any of theinitial components, including the polymeric material, can be provided ina flavored form. In some cases, flavorants and/or other additives areincluded in the smokeless tobacco. In some cases, flavorants and/orother additives are absorbed into to the smokeless tobacco product afterthe polymeric material and the tobacco are combined. In some cases,flavorants and/or other additives are sprayed onto a stream as part of aquenching and/or surfactant mist. Alternatively or additionally, flavorcan be applied prior to being further processed (e.g., cut or punchedinto shapes) or flavor can be applied prior to packaging.

Suitable flavorants include wintergreen (e.g., methyl salicylate),cherry and berry type flavorants, various liqueurs and liquors such asDramboui, bourbon, scotch, whiskey, spearmint, peppermint, lavender,cinnamon, cardamon, apium graveolents, clove, cascarilla, nutmeg,sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemonoil, orange oil, Japanese mint, cassia, caraway, cognac, jasmin,chamomile, menthol, ilangilang, sage, fennel, piment, ginger, anise,coriander, coffee, liquorish, and mint oils from a species of the genusMentha. Mint oils used in some cases of the fiber-wrapped smokelesstobacco products include spearmint and peppermint.

Flavorants can also be included in the form of flavor beads (e.g.,flavor capsules, flavored starch beads, flavored gelatin beads), whichcan be dispersed within the fiber-wrapped smokeless tobacco product(e.g., in a nonwoven network of polymeric structural fibers). Forexample, the fiber-wrapped smokeless tobacco product could include thebeads described in U.S. Patent Application Publication 2010/0170522,which is hereby incorporated by reference.

In some cases, the amount of flavorants in the fiber-wrapped smokelesstobacco product is limited to less than 10 weight percent in sum. Insome cases, the amount of flavorants in the fiber-wrapped smokelesstobacco product is limited to be less than 5 weight percent in sum. Forexample, certain flavorants can be included in the fiber-wrappedsmokeless tobacco product in amounts of about 3 weight percent.

Other optional additives include as fillers (e.g., starch, di-calciumphosphate, lactose, sorbitol, mannitol, and microcrystalline cellulose),soluble fiber (e.g., Fibersol from Matsushita), calcium carbonate,dicalcium phosphate, calcium sulfate, and clays), lubricants (e.g.,lecithin, stearic acid, hydrogenated vegetable oil, canola oil, mineraloil, polyethylene glycol 4000-6000 (PEG), sodium lauryl sulfate (SLS),glyceryl palmitostearate, sodium benzoate, sodium stearyl fumarate,talc, and stearates (e.g., Mg or K), and waxes (e.g., glycerolmonostearate, propylene glycol monostearate, and acetylatedmonoglycerides), plasticizers (e.g., glycerine), propylene glycol,polyethylene glycol, sorbitol, mannitol, triacetin, and 1,3 butanediol), stabilizers (e.g., ascorbic acid and monosterol citrate, BHT, orBHA), artificial sweeteners (e.g., sucralose, saccharin, and aspartame),disintegrating agents (e.g., starch, sodium starch glycolate, crosscaramellose, cross linked PVP), pH stabilizers, salt, or other compounds(e.g., vegetable oils, surfactants, and preservatives). Some compoundsdisplay functional attributes that fall into more than one of thesecategories. For example, propylene glycol can act as both a plasticizerand a lubricant and sorbitol can act as both a filler and a plasticizer.As noted above, fillers or colorants can be added to the polymer priorto melt-blowing the polymer in order to increase the permittivity of thewrapped fibers.

Oven volatiles, such as water, may also be added to the fiber-wrappedsmokeless tobacco product to bring the oven volatiles content of thefiber-wrapped smokeless tobacco product into a desired range. In somecases, flavorants and other additives are included in a hydratingliquid.

Oven Volatiles

The fiber-wrapped smokeless tobacco product can have a total ovenvolatiles content of between 10 and 61 weight percent. In some cases,the total oven volatiles content is at least 40 weight percent. The ovenvolatiles include water and other volatile compounds, which can be apart of the tobacco, the polymeric material, the flavorants, and/orother additives. As used herein, the “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110 degrees C. for 3.25hours. Some of the processes may reduce the oven volatiles content(e.g., heating the composite or contacting the smokeless tobacco with aheated polymeric material), but the processes can be controlled to havean overall oven volatiles content in a desired range. For example, waterand/or other volatiles can be added back to the fiber-wrapped smokelesstobacco product to bring the oven volatiles content into a desiredrange. In some cases, the oven volatiles content of the fiber-wrappedsmokeless tobacco product is between 4 and 61 weight percent. In somecases, the oven volatiles content of the fiber-wrapped smokeless tobaccoproduct is between 47 and 61 weight percent. For example, the ovenvolatiles content of smokeless tobacco used in the various processeddescribed herein can be about 57 weight percent. In some cases, the ovenvolatiles content can be between 10 and 30 weight percent.

Product Configurations

An exemplary shape of a fiber-wrapped smokeless tobacco product 600provided herein is shown in FIG. 6. FIG. 6 depicts a perspective view ofthe fiber-wrapped smokeless tobacco product 600 having a substantiallyrectangular cuboidal shape with rounded corners in the longitudinal(lengthwise) plane. In some cases, the preformed smokeless tobaccoproduct has a substantially rectangular cuboidal shape having a lengthof between 15 mm and 50 mm, a width of between 5 mm and 20 mm, and athickness of between 3 mm and 12 mm. For example, a substantiallyrectangular cuboidal shape could have a length of between 26 mm and 30mm, a width of between 10 mm and 12 mm, and a thickness of between 6 mmand 8 mm. A product having a length of 28 mm, a width of 11 mm, andthickness of 7 mm could have a product weight of about 2.35 g. In otherembodiments, a substantially rectangular cuboidal shape could have alength of between 18 and 21 mm, a width of between 10 mm and 12 mm, anda thickness of between 9 mm and 11 mm. In some cases, the preformedsmokeless tobacco product 600 can be cube shaped. A smokeless tobaccoproduct as described herein can have a number of differentconfigurations, e.g., can have the configuration depicted in FIG. 6, orhave a shape or a layered structure that is different from theparticular embodiment of the fiber-wrapped smokeless tobacco product 600depicted in FIG. 6. In some circumstances, the fiber-wrapped smokelesstobacco product can be configured to be: (A) an elliptical shapedfiber-wrapped smokeless tobacco product; (B) an elongated ellipticalshaped fiber-wrapped smokeless tobacco product; (C) a semi-circularfiber-wrapped smokeless tobacco product; (D) a square- orrectangular-shaped fiber-wrapped smokeless tobacco product; (E) afootball-shaped fiber-wrapped smokeless tobacco product; (F) anelongated rectangular-shaped fiber-wrapped smokeless tobacco product;(G) boomerang-shaped fiber-wrapped smokeless tobacco product; (H) arounded-edge rectangular-shaped fiber-wrapped smokeless tobacco product;(I) teardrop- or comma-shaped fiber-wrapped smokeless tobacco product;(J) bowtie-shaped fiber-wrapped smokeless tobacco product; and (K)peanut-shaped fiber-wrapped smokeless tobacco product. Alternatively,the smokeless tobacco product can have different thicknesses ordimensionality, such that a beveled fiber-wrapped smokeless tobaccoproduct (e.g., a wedge) is produced or a hemi-spherical shape isproduced.

The smokeless tobacco product can be manipulated in a number ofdifferent ways. For example, particular embodiments of the smokelesstobacco product can be wrapped or coated in an edible or dissolvablefilm. The dissolvable film can readily dissipate when the smokelesstobacco product is placed in a mouth of an adult tobacco consumer. Inaddition, or in the alternative, some embodiments of the smokelesstobacco products can be embossed or stamped with a design (e.g., a logo,an image, a trademark, a product name, or the like). For example, adesign also can be embossed or stamped into those embodiments having adissolvable film applied thereto.

In some cases, the fiber-wrapped smokeless tobacco product is used incombination with other tobacco and non-tobacco ingredients to form avariety of smokeless tobacco products. For example, the fiber-wrappedsmokeless tobacco product can include flavor beads.

Other Embodiments

It is to be understood that, while the invention has been describedherein in conjunction with a number of different aspects, the foregoingdescription of the various aspects is intended to illustrate and notlimit the scope of the invention, which is defined by the scope of theappended claims. Other aspects, advantages, and modifications are withinthe scope of the following claims.

Disclosed are methods and compositions that can be used for, can be usedin conjunction with, can be used in preparation for, or are products ofthe disclosed methods and compositions. These and other materials aredisclosed herein, and it is understood that combinations, subsets,interactions, groups, etc. of these methods and compositions aredisclosed. That is, while specific reference to each various individualand collective combinations and permutations of these compositions andmethods may not be explicitly disclosed, each is specificallycontemplated and described herein. For example, if a particularcomposition of matter or a particular method is disclosed and discussedand a number of compositions or methods are discussed, each and everycombination and permutation of the compositions and the methods arespecifically contemplated unless specifically indicated to the contrary.Likewise, any subset or combination of these is also specificallycontemplated and disclosed

What is claimed is:
 1. A method of enrobing a product portion in polymerstrands comprising: mounting at least one product portion on a holdingdevice, the holding device passing at least partially through a body ofsaid at least one product portion; producing a flow of polymeric fibersfrom a polymer spray head to create a polymer enrobing zone; moving saidholding device to pass said at least one product portion through saidpolymer enrobing zone such that a plurality of said polymeric fiberswraparound said at least one product portion to produce an enrobedproduct portion; and removing at least a portion of said holding devicefrom said enrobed product portion.
 2. The method of claim 1, wherein theholding device is a needle that passes at least partially through saidbody of said at least one product portion.
 3. The method of claim 2,wherein said needle passes entirely through said body of said at leastone product portion.
 4. The method of claim 2, wherein said needle isentirely removed from said enrobed product portion.
 5. The method ofclaim 2, wherein said needle is metal.
 6. The method of claim 2, whereinsaid needle is heated before or during said passing of said at least oneproduct portion through said polymer enrobing zone.
 7. The method ofclaim 1, wherein said holding device is a string.
 8. The method of claim7, wherein said string comprises cellulosic fibers, polymeric fibers, ora combination thereof.
 9. The method of claim 7, wherein removing atleast a portion of said holding device comprises cutting said stringsuch that at least a portion of said string remains within productportion.
 10. The method of claim 1, wherein mounting the at least oneproduct portion on said holding device comprises forming the at leastone product portion around said holding device.
 11. The method of claim1, wherein said passing said at least one product portion through saidpolymer enrobing zone comprises rotating said at least one productportion.
 12. The method of claim 1, wherein said passing said at leastone product portion through said polymer enrobing zone compriseschanging the orientation of said at least one product portion.
 13. Themethod of claim 1, further comprising collecting at least some of saidplurality of polymeric fibers on a polymer collection roller positionedopposite said polymer enrobing zone.
 14. The method of one of claim 1,wherein said at least one product portion comprises a consumableproduct.
 15. The method of claim 14, wherein said at least one productportion comprises tobacco.
 16. The method of claim 15, wherein said atleast one product portion comprises smokeless tobacco.
 17. The method ofclaim 14, wherein said at least one product portion has an overall ovenvolatiles content of about 4% by weight to about 61% by weight.
 18. Themethod of claim 14, wherein said at least one product portion comprisesa binder.
 19. The method of claim 18, wherein said at least one productportion comprises between 0.1 and 0.5 weight percent of a binder. 20.The method of claim 18, wherein the binder comprises guar gum, xanthangum, cellulose gum, or a combination thereof.
 21. The method of claim 1,wherein a surfactant is applied to the plurality of polymeric fibers asthey exit the polymer spray head.
 22. The method of claim 1, wherein theat least one product portion is enrobed in a covering of polymericfibers while in said polymer enrobing zone having a basis weight of lessthan 40 gsm.
 23. The method of claim 1, wherein the polymeric fibersenrobing said at least one product portion have a diameter of less than100 microns.
 24. The method of claim 23, wherein the polymeric fibersenrobing said at least one product portion have a diameter of less than30 microns.
 25. The method of claim 1, further comprising applying anelectrostatic charge to said plurality of polymeric fibers, said atleast one product portion, or a combination thereof.
 26. The method ofclaim 1, wherein the polymeric fibers are above a melt temperature forthe polymer when impacting the at least one product portion such thatthey conform to structures on the exterior of said at least one productportion.
 27. The method of claim 1, wherein the polymer spray head is amelt-blowing apparatus that melt-blows the polymeric fibers in saidupward direction.
 28. The method of claim 27, wherein the polymericfibers are melt-blown fibers having a diameter of between 0.5 and 10.0microns.
 29. The method of claim 1, wherein the polymeric fibers arecentrifugal force spun fibers having a diameter of between 0.01 micronsand 1.0 micron.
 30. The method of claim 1, wherein the melt-blownpolymeric fibers are quenched below a melt temperature of the polymerupon impacting the body.
 31. The method of claim 1, wherein thepolymeric fibers comprise polypropylene.
 32. The method of claim 1,wherein the polymeric fibers comprise polyurethane.
 33. The method ofclaim 1, wherein the polymeric fibers comprise at least two differentmaterials.
 34. The method of claim 33, wherein the at least twodifferent polymeric materials are coextruded to form composite polymericfibers of the two polymeric materials.
 35. The method of claim 33,wherein at least one of the polymeric materials is mouth-stable and atleast one of the polymeric materials is mouth-dissolvable.
 36. Themethod of claim 1, wherein the polymeric fibers comprise a colorant. 37.An apparatus for enrobing a product portion comprising a. a polymerspray head arranged to direct a plurality of polymeric fibers into apolymer enrobing zone; and b. at least one holding device adapted tohold at least one product portion, the at least one holding device beingadapted to be moved through said polymer enrobing zone.
 38. Theapparatus of claim 37, further comprising a molding device adapted toform at least one product portion in at least one mold cavity.
 39. Theapparatus of claim 38, wherein said molding device is adapted to formsaid at least one product portion around said holding device.
 40. Theapparatus of claim 37, further comprising a robotic arm adapted insertsaid at least one holding device into said at least one mold cavity andto move said holding device between said molding device and said polymerenrobing zone.
 41. The apparatus of claim 37, further comprising acutting device adapted to cut at least a portion of said holding device.42. The apparatus of claim 37, further comprising a heating deviceadapted to heat said holding device.
 43. The apparatus of claim 37,wherein said apparatus is adapted to rotate said holding device.
 44. Theapparatus of claim 37, wherein said apparatus is adapted to change theorientation of said holding device.
 45. The apparatus of claim 37,further comprising a polymer collection roller opposite said polymerenrobing zone adapted to collect polymeric fibers that are not wrappedaround product portions passing through said polymer enrobing zone. 46.The apparatus of claim 37, wherein said polymer spray head is elongated.47. A seamless fiber-wrapped smokeless tobacco product comprising: abody comprising smokeless tobacco; a plurality of melt-blown orcentrifugal force spun polymeric fibers surrounding the smokelesstobacco; and a string segment passing through said body.
 48. The productof claim 47, wherein the melt-blown polymeric fibers have a basis weightof less than 5 gsm.